Method and system for manufacturing noodles of structural joints

A method of manufacturing a noodle of a structural joint, comprising:

• pulling a first composite sheet through a first splitting station to cut the first composite sheet into a plurality of first composite plies;
• pulling the plurality of first composite plies through a first alignment station to stack the plurality of first composite plies on top of each other to form a first stacked composite layup;
• pulling the first stacked composite layup through a first heating station to heat the first stacked composite layup to form a first heated composite layup;
• pulling the first heated composite layup through a first forming station to shape the first heated composite layup into a first pre-selected cross-sectional shape to form at least a first portion of a continuous noodle;
• pulling at least the first portion of the continuous noodle through a cutting station to cut at least the first portion of the continuous noodle to a pre-selected length;
• pulling a second composite sheet through a second splitting station to cut the second composite sheet into a plurality of second composite plies;
• pulling the plurality of second composite plies through a second alignment station to stack the plurality of second composite plies on top of each other to form a second stacked composite layup;
• pulling the second stacked composite layup through a second heating station to heat the second stacked composite layup to form a second heated composite layup;
• pulling the second heated composite layup through a second forming station to shape the second heated composite layup into a second pre-selected cross-sectional shape to form an intermediate composite layup;
• pulling the intermediate composite layup through the first heating station to heat the intermediate composite layup to form a heated intermediate composite layup;
• pulling the heated intermediate composite layup through the first forming station to couple together the heated intermediate composite layup and the first heated composite layup and shape the intermediate composite layup into a third pre-selected cross-sectional shape to form at least a second portion of the continuous noodle;
• and
• pulling at least the second portion of the continuous noodle, together with at least the first portion of the continuous noodle, through the cutting station to concurrently cut at least the first portion and the second portion of the continuous noodle to the pre-selected length.